Lightweight casket

ABSTRACT

A lightweight structurally sound casket formed preferably of a sandwich construction using a core of an open cell or honeycomb patterned material and fluid resistant surface elements. The casket is comprised of a body containment portion and a lid portion, each of which has the sandwich construction as the main structural element. The open cell material is structurally enhanced by being sandwiched between first and second stabilizing surface elements in both the body containment portion and the lid portion. In addition to the stabilizing surface elements, an aesthetically pleasing material is adhered to the outer portions of the body containment section and lid so that the casket has an attractive appearance.

This application is a continuation of Ser. No. 09/819,840, filed Mar.28, 2001, now abandoned, which is a continuation of Ser. No. 09/491,209,filed Jan. 25, 2000, now abandoned, which is a continuation of Ser. No.09/324,254, filed Jun. 2, 1999, now Pat. No. 6,138,334, which is adivisional of Ser. No. 08/495,323, filed Jun. 27, 1995, now Pat. No.5,685,937, which is a continuation of Ser. No. 08/124,638, filed Sep.22, 1993, now abandoned.

BACKGROUND OF THE INVENTION

This invention relates to caskets or coffins used to house the remainsof once living organisms. More particularly, this invention is directedtoward a lightweight yet structurally strong casket highly suitable forcremation-type and interment ceremonies. The casket exhibits excellentstructural integrity while being highly flammable and minimally harmfulto the environment.

The riddance of the bodies of the deceased can be accomplished inseveral ways, including burial and cremation. Because of the growingconcern for the world's environment, both of these methods have beenhighly scrutinized. Environmental problems include the overpopulation ofcemeteries and the effects of placing a corpse into the ground. Inaddition, environmental concerns arise from cremation, which is done inpart to alleviate the concerns regarding burial, wherein harmfulvolatile organic compounds (VOC's) are released to the atmosphere viathe burning of environmentally unsafe materials which are often used tomanufacture caskets or coffins.

In response to the environmental concerns surrounding cremation and inresponse also to the ever-rising costs of coffins and/or caskets forburial, inexpensive, lightweight and environmentally safe caskets havebeen developed. Most of these caskets are constructed from corrugatedcardboard or the like. Corrugated cardboard tends to absorb moisture anddegrades structurally when it is exposed thereto. However, because ofthe inadequate structural integrity of corrugated cardboard caskets,such caskets tend to twist and bend thereby threatening the security ofthe corpse therein and risking the stability of the mental health offriends and relatives who may unwantingly witness an unscheduled viewingof the deceased should the casket fail.

In the prior art, for example, the patent to Elder, U.S. Pat. No.4,967,455 discloses a cardboard casket and a method of manufacturing thesame. The patent discloses a corrugated cardboard casket constructedfrom multiple blanks of cardboard which are attached and folded tocreate the enclosure which forms the casket. However, as can be seenfrom the drawing and the text, only the use of corrugated cardboard isdisclosed. Corrugated cardboard, which is currently and predominantlyused in making lightweight caskets, inherently lacks structuralintegrity and, therefore, causes things made from it to also lackstructural integrity. Therefore, the casket in Elder poses the risk ofstructural failure.

For the morbid partygoer, U.S. Pat. No. 4,891,859 to Nutting, disclosesa cardboard coffin for use at parties or similar occasions which isformed from a plurality of corrugated cardboard blanks. Again, thecoffin is constructed by folding the corrugated cardboard into the shapeof the casket or coffin. As with Elder, the use of the corrugatedcardboard fails to provide the coffin with the necessary strength andstructural rigidity of a more expensive coffin constructed from strongermaterials.

While the foregoing patents disclose the use of cardboard forconstructing a more economical and environmentally safe casket, none ofthe prior patents discloses the use of polymer coated cellulose fiber(PCCF) or other material arranged in an open cell pattern or otherpatterns exhibiting similar high strength when constructed in accordancewith this invention.

SUMMARY OF THE INVENTION

The invention disclosed herein is directed toward an economical andenvironmentally safe casket having excellent structural integrity formaintaining the shape of the casket and for exhibiting low torsionaldisplacement during the carrying of the deceased. These properties areexhibited even when the casket is exposed to a high moistureenvironment.

In accordance with the invention, the lightweight casket comprises abody containment compartment and a lid constructed from a core sectionof polymer coated cellulose fiber (PCCF) arranged in an open cellpattern. The core section for both the lid and for the body containmentportion is comprised of a first and a second surface, wherein eachsurface is attached to a stabilizing surface element thereby causing asandwich-type effect. Additionally, the core of this sandwich could bemade of a solid surface structural material such as polystyrene foam.

The core section may be comprised of a plurality of honeycomb cellswherein each cell is substantially a cylindrically shaped tube. Thestabilizing surface elements are surface-treated planar sheets glued orotherwise attached to the open cell patterned core of PCCF. Thecombination of the open cell pattern core and the sandwiching effect viathe stabilizing surface elements, supplies the structural rigidity ofthe casket. The core material provides the shear force for carrying thesandwich construction while the stabilizing surface elements carry thebending forces of the sandwich. The core material having the open cellsperpendicular to the stabilizing surface elements exhibit a muchstronger and stiffer structural shear carrying member than alongitudinally aligned corrugated configuration.

This invention also includes the method of constructing the lightweightcasket. The open cell patterned core section is first cut into arectangular pattern suitable in size for folding into the bodycontainment section. A first stabilizing surface element is attached tothe underside of the core section, and a second stabilizing surfaceelement comprising a plurality of sections is similarly attached to theupper portion of the core section but arranged in a pattern allowing thefolding of the core section into the body containment section. Duringbonding of the stabilizing surface elements thereto, the core acts as apressure transfer mechanism to assure proper bonding. Upon folding, thewalls and bottom of the body containment section are established and areadhered to each other for maintaining the enclosure-type structure.Finally, a lid is formed in a similar manner from a core section andstabilizing surface elements which are caused to form a dome-like shapevia use of a jig and the application of air pressure.

The casket disclosed is lightweight yet structurally rigid forsupporting and carrying the contents placed therein. By using PCCF inlieu of more expensive materials, economic and environmental concernsare precluded while a very strong lightweight structure is establishedvia the use of the open cell pattern and stabilizing surface elements.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of illustrating the invention, there is shown in theaccompanying drawings one form which is presently preferred; it beingunderstood that the invention is not intended to be limited to theprecise arrangements and instrumentalities shown.

FIG. 1 is a perspective view of a lightweight casket constructed inaccordance with the principles of the present invention;

FIG. 2 is a partial cross sectional view taken along line 2 of FIG. 1;

FIG. 3a discloses the use of a polystyrene based, solid surface, core inlieu of the honeycomb, open cell structure, core;

FIG. 3 is a perspective view of the honeycomb core and first stabilizingsurface element;

FIG. 4 is a perspective view of the honeycomb core attached to the firstand second stabilizing surface elements;

FIG. 5 is a view similar to FIG. 4 with the addition of a second layerof core section attached to the inner bottom surface of the casket;

FIG. 6 Is a perspective view of the lightweight casket during thefolding stage;

FIG. 7 is a perspective exploded view of the casket showing theinsertion of the end inserts;

FIG. 8 is a perspective view of the body containment portion of thecasket prior to the addition of aesthetic features;

FIG. 9 is a cross sectional view taken along line 9—9 of FIG. 8;

FIG. 10 is an exploded view of the method of construction of the casketlid using a jig;

FIG. 11 is a perspective view of the casket lid and jig with the jigcover in the open position;

FIG. 12 is a perspective view of the jig cover and air pressureconnector, and

FIG. 13 is a cross-sectional view taken along line 13—13 of FIG. 12.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings in detail wherein like reference numeralshave been used throughout the various figures to designate likeelements, there is shown in FIG. 1 a perspective view of the lightweightcasket constructed in accordance with the principles of the presentinvention and designated generally as 10. The casket 10 is comprisedessentially of the body containment portion 12 and the lid section 14.As shown in FIG. 2 for the body containment portion, it is comprisedlargely of the open cell core section 16, preferably a honeycombpattern, being sandwiched between a first stabilizing surface element 18and a second stabilizing surface element 20, both of which are formedfrom a fluid resistant material. The lid 14 is constructed in asimilarly layered manner.

The formation of the body containment portion 12 is accomplished in partas shown in FIG. 3. The honeycomb core 16 is cut to a substantiallyrectangular shape and of a size adapted to be folded into the casket. Informing the body containment portion 12, the first stabilizing surfaceelement 18 is placed underneath the honeycomb core 16, while the secondstabilizing surface element 20 is placed on top of the honeycomb core16, as shown in FIG. 4. The first stabilizing surface element 18 issubstantially rectangular in shape and scored with fold lines, as shownin FIG. 3, as well as being cut in four places 24 a through 24 d. Thefirst stabilizing surface element 18, as shown, is larger in length thanthe core section 16. The fold lines and the cuts 24 a through 24 dfunction to facilitate the folding of the honeycomb core with thestabilizing surface elements attached thereto into the enclosure asshown in FIGS. 6, 7 and 8. The fold lines are not shown but are merelycontinuations of the cuts 24 a through 24 d as well as beingperpendicular to those cuts adjacent the edge of the core section 16.

The honeycomb core 16 is preferably formed from polymer coated cellulosefiber (PCCF) sheets but environmentally safe plastic or the like willalso suffice. The core is comprised of a plurality of longitudinallyextending cylindrically shaped cells interconnected and forming ahoneycomb pattern. Because of their cylindrical shape, the members havestrong structural rigidity along their longitudinal axes.

With the first stabilizing surface element 18 being scored and cut forfolding, the honeycomb core 16 is adhered to the upper surface thereofutilizing any suitable adhesive. In addition, an aesthetically pleasingmaterial 26 is adhered to the underside of the first stabilizing surfaceelement 18 for incorporating a pleasing texture and appearance to thecasket. The second stabilizing surface element 20 is similarly adheredto the honeycomb core. However, the stabilizing surface element 20 iscomprised of a plurality of separate sections 28 a through 28 c. Thesections 28 a through 28 c comprise three rectangularly-shaped planersheets which are arranged upon the honeycomb core as shown in FIG. 4. Ascan be seen, the separate sections are of sizes which allow spacesbetween the sections leaving rectangular portions 30 a and 30 b ofexposed honeycomb.

In a second embodiment, these spaces of core material left between thestabilizing elements may be cut on a forty five degree angle from thestabilizing element edges to the middle of the space. These angled cutshelp to facilitate the folding of the core material and stabilizingelements into the body containment section. In a third embodiment, thecore material between the stabilizing elements is removed and insertsare placed in the spaces for additional support.

The purpose of the sandwiching effect of the honeycomb core between thetwo stabilizing sections is to provide the honeycomb core withstructural rigidity by maintaining the cells of the core in asubstantially perpendicular orientation to applied forces. The core actsas a pressure transfer mechanism and transfers the load to the outerstabilizing surface element 18 when a force is applied thereto. Byleaving uncovered the exposed honeycomb core sections 30 a and 30 b, asprovided for by the separate sections, the exposed honeycomb lacks thestructural rigidity of the sandwiched honeycomb core. These exposed and,therefore, weaker sections of honeycomb inherently create fold lines onthe core surface.

In addition to the core 16, an additional layer 32 of core, as shown inFIG. 5, is glued to the structure over the center portion 28 b of thesecond stabilizing surface element 20. The additional core 32 is ofsubstantially the same size as the center portion 28 b and in additionhas a third stabilizing surface element 34 glued to the top thereof. Theadditional honeycomb core and stabilizing surface further strengthensand increases the structural rigidity of the casket bottom and providesextra structural security.

Referring now to FIGS. 5 and 6, the lightweight casket is now ready forformation into the body containment portion 12. To initiate thisprocess, the sides of the casket 36 a and 36 b are folded upward alongthe fold lines (not shown), cut lines 24 a through 24 d and therectangular and exposed honeycomb sections 30 a and 30 b. By followingthis procedure, the formation shown in FIG. 6 is the result. Uponfolding the sides 36 a and 36 b, the corners 38 a through 38 d must befolded inward towards the center of the body containment portion 12. Asshown in FIG. 6, the corners 38 a through 38 d become part of the endsof the body container portion 12. However, the ends are furthercompleted by folding upward the end extensions 40 a and 40 b toward thefolded corners 38 a through 38 d. Before folding the extensions 40 a and40 b, adhesive is applied on the contact surfaces thereof for adherenceto the outside surfaces of the folded corners 38 a through 38 d. Thisprovides a double shear path and increases the strength of theenclosure.

Referring now to FIG. 7, the body containment portion is ready forinsert of the end inserts 42 a and 42 b. Each end insert is comprised ofthe rectangular portion of honeycomb material having a stabilizingsurface element 44 adhered thereto. The stabilizing surface elements 44a and 44 b are adhered to the surface of the end inserts 42 a and 42 bfacing the inner portion of the body containment portion 12 wherein theend extensions 40 a and 40 b act as the other stabilizers for theinserts 42 a and 42 b, respectively. Accordingly, the end inserts areinserted adjacent each end of the body containment portion. The side ofeach end insert having no stabilizing surface element adhered thereto isplaced adjacent and adhered to the inner surfaces of the folded corners38 a through 38 d, the end insert 42 a being adhered to folded corners38 a and 38 d, and end insert 42 b being adhered to folded corners 38 band 38 c. At this point in the construction process, the lightweightcasket resembles the configuration shown in FIG. 8 wherein the bodycontainment portion 12 is fully constructed.

The lid of the lightweight casket is fabricated as shown in FIGS. 10-13.Similar to the body containment portion, the lid 14 is formed by placinga lid core section comprised of a honeycomb portion 46 between two lidstabilizing surface elements 48 a and 48 b as shown in FIG. 10. Due tothe curved shape of the lid, the construction of it requires a somewhatdifferent process than the construction of the body containment portion12. The preferred method of constructing the lid 14 is to construct ajig 50 having an outer portion resembling the shape of the lid 14. Thejig 50 is used to construct the lid 14 in a step-like manner whichincludes the application of a pressure source 52.

As shown in FIG. 10, the jig 50 has an outer section 51 which issubstantially in the shape of the lid 14 shown in FIG. 1. To initiatethe lid construction process, the first stabilizing surface element 48 ais placed into the jig 50. As shown in FIG. 10, the first stabilizingsurface element is constructed from one to three separate elements, acenter element and two triangularly-shaped end elements. These elementsare placed into jig 50. Each of the elements has an edge 54 formed intoa rectangular shape and adapted to receive perimeter stabilizing bars 56a through 56 d. The perimeter stabilizing bars 56 a through 56 d formthe portion of the lid which contacts the body containment portion 12.It is important that the edges which contact the body containmentportion 12 have structural rigidity as well as the lid itself.Therefore, the perimeter bars 56 a through 56 d are placed into thefolded edges 54 a-54 d and secured therein by adhering the edges 54 a-54d thereto.

Referring still to FIG. 10, the honeycomb portion 46, similar to thatused with the body containment portion, is now placed into the jig 50and over the first stabilizing surface element 48 a. Prior to the insertof the honeycomb 46, adhesive is spread over the first stabilizingsurface element 48 a for causing the honeycomb portion 46 to adherethereto. The honeycomb portion 46 is a substantially rectangular pieceof material which is cut to a size which conforms to the lid shape andstill contacts the entire surface of the entire first stabilizingsurface element. It is not necessary to cut or provide fold lines in thehoneycomb portion 46 in any manner due to the flexibility of the same inconforming to the general shape of the lid 14.

With the honeycomb portion 46 inserted therein, the second stabilizingsurface element 48 b is placed over the top of the inserted honeycombportion 46. The second stabilizing surface element 48 b is rectangularbut is comprised of an odd shaped section 58 having triangularly shapedbut integral end sections 59 a and 59 b and having angular fold cuts asshown in FIG. 10. These sections 58 and 59 a and 59 b are placed on thehoneycomb portion 46 as shown in FIG. 11 and conform to the jig 50.Prior to placement onto the honeycomb portion 46, adhesive is applied tothe side of the sections which will contact the honeycomb portion 46.With all the elements in place, a pressure source 52 is applied to theintegrated sections.

As shown in FIGS. 11 and 12, a flexible cover 60 is hinged to andextends from the edges of the jig 50 via a hinged door 61 and is placedover the integrated elements just discussed, forming an air tight seal.The pressure source connector 62 extends from the flexible portion 60 soas to connect the pressure source 52 thereto. Accordingly, the pressuresource 52 is connected to the connector 62 and pressure is applied tothe lid 16. The pressure thereby forces the integrated sections togetherfor adhering those which are contacting each other and forcing them intothe shape of the jig 50. In addition, an aesthetically pleasing layer 64is applied to the lid 16 for matching the body containment portion 12.When the air is removed and the sections are adhered together, the jigis disassembled and the lid can be removed, resembling the configurationshown in FIG. 1.

The lid can also be formed in separate halves which is desirable forviewing purposes. The formation of the lid into two separate halves isperformed essentially the same as just described except that each halfis constructed separately in the jig such that finished edges are formedall around.

For both the body containment portion 12 and the lid 14, materials andpatterns other than PCCF arranged in a honeycomb pattern can be used. Asshown in FIG. 3a, for example, an environmentally safe polystyrene-typematerial 65 can be used in lieu of the honeycomb material where it isplaced between two stabilizing surface elements. Polystyrene foam placedbetween similar stabilizing surface elements exhibits substantially thesame structural rigidity as the honeycomb portions and can be usedinterchangeably. Additionally, PCCF and other materials can be formedinto truss patterns which also exhibit high structural rigidity whensandwiched between the stabilizing surface elements.

Upon completion of the body containment portion 12 and the lid 14 assubstantially described, the lightweight casket is finished by attachingornamental elements thereto which gives the casket a richer appearance.As shown in FIG. 1, preformed corner pieces 66 a through 66 d are placedonto the corners of the lightweight casket 10. In addition toappearance, the corners 66 a-66 d provide extra strength in the bodycontainment portion 12. The corners 66 a through 66 d are comprisedsubstantially of two triangularly-shaped elements attachedperpendicularly to each other. The corners are covered with the sameaesthetically pleasing material as the rest of the lightweight casketexhibits. The corners 66 a through 66 d are simply glued to the bodycontainment compartment corners as shown in FIG. 1. In addition to thecorners, handles 68 are securely attached to each side of thelightweight casket for the carrying of the same. The inner portion ofthe lightweight casket in its finished condition is also designed in anaesthetically pleasing manner having linings and pillows.

The lightweight casket is used in a manner similar to any other casket.Because of the structural rigidity providing by the sandwiching ofeither the open cell or solid surface core materials, there are nospecial precautions which must be considered in handling the lightweightcasket 10. The body is simply placed in the casket as with any othercasket and it can be carried similar to any other casket. For cremationpurposes, the casket is highly flammable and, as discussed, is notharmful to the environment and can simply be placed into the furnacewithout alteration.

The present invention may be embodied in other specific forms withoutdeparting from the spirit or essential attributes thereof andaccordingly reference should be made to the appended claims rather thanto the foregoing specification as indicating the scope of the invention.

What is claimed is:
 1. A casket comprising: a body containment portionhaving a bottom and at least one wall extending upwardly from saidbottom; said bottom and said at least one wall constructed as a sandwichstructure; said sandwich structure having a core and first and secondopposed surface elements attached to first and second opposed surfacesof said core; one of said core and said first surface element beingdiscontinuous and the other of said core and said first surface elementbeing continuous at a juncture of said bottom and wall to facilitatefolding a planar blank of said sandwich structure into said bodycontainment portion.
 2. The casket of claim 1 wherein said core isdiscontinuous.
 3. The casket of claim 1 wherein said first surfaceelement is discontinuous.
 4. The casket of claim 1 wherein said core andsaid first surface element are discontinuous.
 5. The casket of claim 1wherein said core has a plurality of open cells.
 6. The casket of claim1 wherein said core is honeycomb.
 7. The casket of claim 1 wherein saidcore has solid surfaces.
 8. The casket of claim 7 wherein said core ispolystyrene foam.
 9. The casket of claim 1 wherein said surface elementsare substantially liquid impervious.
 10. The casket of claim 1 furtherincluding an aesthetically pleasing outer layer of material attached tosaid second surface element.
 11. The casket of claim 1 wherein saidbottom of said body containment portion is comprised of first and secondlayers of core which are attached to a third surface element interposedtherebetween.
 12. The casket of claim 1 further comprising a lidconstructed as a sandwich structure having a core and first and secondopposed surface elements attached to first and second opposed surfacesof said lid core.
 13. The casket of claim 12 wherein said lid core has aplurality of open cells.
 14. The casket of claim 13 wherein said lidcore is honeycomb.
 15. The casket of claim 12 wherein said lid core hassolid surfaces.
 16. The casket of claim 15 wherein said lid core ispolystyrene foam.
 17. A casket comprising: a shell and a lid enclosingsaid shell; at least one of said shell and lid constructed as a sandwichstructure; said sandwich structure having a core and first and secondopposed surface elements attached to first and second opposed surfacesof said core; one of said core and said first surface element beingdiscontinuous and the other of said core and said first surface elementbeing continuous thereby forming a fold line about which to fold aplanar blank of said sandwich structure into one of said shell and lid.18. The casket of claim 17 wherein the planar blank of said sandwichstructure is folded into said shell.
 19. The casket of claim 18 whereinsaid shell has a bottom and at least one wall extending upwardly fromsaid bottom.
 20. The casket of claim 19 wherein said one of said coreand said first surface element is discontinuous at a juncture of saidbottom and wall.
 21. The casket of claim 17 wherein said core isdiscontinuous.
 22. The casket of claim 17 wherein said first surfaceelement is discontinuous.
 23. The casket of claim 17 wherein said coreand said first surface element are discontinuous.
 24. The casket ofclaim 17 wherein said core has a plurality of open cells.
 25. The casketof claim 24 wherein said core is honeycomb.
 26. The casket of claim 7wherein said core has solid surfaces.
 27. The casket of claim 26 whereinsaid core is polystyrene foam.
 28. The casket of claim 17 wherein saidsurface elements are substantially liquid impervious.
 29. The casket ofclaim 17 further including an aesthetically pleasing outer layer ofmaterial attached to said second surface element.
 30. The casket ofclaim 17 said bottom of said shell is comprised of first and secondlayers of core which are attached to a third surface element interposedtherebetween.